Rosemount FCLi Owner's manual

Brand: Rosemount

Model: FCLi

Type: Owner's manual

Instruction Manual

LIQ-MAN-FCLi-1056, Rev E

July 2017

FCLi with 1056

Transmitter

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Your purchase from Rosemount, Inc. has resulted in

one of the finest instruments available for your

particular application. These instruments have been

designed, and tested to meet many national and

international standards. Experience indicates that

its performance is directly related to the quality of

the installation and knowledge of the user in oper-

ating and maintaining the instrument. To ensure

their continued operation to the design specifica-

tions, personnel should read this manual thoroughly

before proceeding with installation, commissioning,

operation, and maintenance of this instrument. If

this equipment is used in a manner not specified by

the manufacturer, the protection provided by it

against hazards may be impaired.

• Failure to follow the proper instructions may

cause any one of the following situations to

occur: Loss of life; personal injury; property dam-

age; damage to this instrument; and warranty

invalidation.

• Ensure that you have received the correct model

and options from your purchase order. Verify that

this manual covers your model and options. If

not, call 1-800-854-8257 or 949-757-8500 to

request correct manual.

• For clarification of instructions, contact your

Rosemount representative.

• Follow all warnings, cautions, and instructions

marked on and supplied with the product.

• Use only qualified personnel to install, operate,

update, program and maintain the product.

• Educate your personnel in the proper installation,

operation, and maintenance of the product.

• Install equipment as specified in the Installation

section of this manual. Follow appropriate local

and national codes. Only connect the product to

electrical and pressure sources specified in this

manual.

• Use only factory documented components for

repair. Tampering or unauthorized substitution of

parts and procedures can affect the performance

and cause unsafe operation of your process.

• All equipment doors must be closed and protec-

tive covers must be in place unless qualified per-

sonnel are performing maintenance.

• If this equipment is used in a manner not speci-

fied by the manufacturer, the protection provided

by it against hazards may be impaired.

ARNING

RISK OF ELECTRICAL SHOCK

Equipment protected throughout by double insulation.

• Installation of cable connections and servicing of this product

require access to shock hazard voltage levels.

• Main power and relay contacts wired to separate power

source must be disconnected before servicing.

• Do not operate or energize instrument with case open!

• Signal wiring connected in this box must be rated at least

240 V.

• Non-metallic cable strain reliefs do not provide grounding

between conduit connections! Use grounding type bushings

and jumper wires.

• Unused cable conduit entries must be securely sealed by

non-flammable closures to provide enclosure integrity in

compliance with personal safety and environmental protection

requirements. Unused conduit openings must be sealed with

NEMA 4X or IP65 conduit plugs to maintain the ingress

protection rating (NEMA 4X).

• Electrical installation must be in accordance with the National

Electrical Code (ANSI/NFPA-70) and/or any other applicable

national or local codes.

• Operate only with front and rear panels fastened and in place

over terminal area.

• Safety and performance require that this instrument be

connected and properly grounded through a three-wire

power source.

• Proper relay use and configuration is the responsibility of the

user.

CAUTION

This product generates, uses, and can radiate radio frequency

energy and thus can cause radio communication interference.

Improper installation, or operation, may increase such interfer-

ence. As temporarily permitted by regulation, this unit has not

been tested for compliance within the limits of Class A comput-

ing devices, pursuant to Subpart J of Part 15, of FCC Rules,

which are designed to provide reasonable protection against

such interference. Operation of this equipment in a residential

area may cause interference, in which case the user at his own

expense, will be required to take whatever measures may be

required to correct the interference.

ARNING

This product is not intended for use in the light industrial,

residential or commercial environments per the instru-

ment’s certification to EN50081-2.

Configure

S1 Measurement

Free Chlorine

pH Independ. Free Cl

Total Chlorine

Monochloramine

Temp Units

QUICK START

GUIDE

FOR FCLi

TRANSMITTER

1. Refer to Section 2.0 for installation instructions and Section 3.0 for wiring instructions.

2. Once connections are secured and verified, apply power to the transmitter.

3. When the transmitter is powered up for the first time, Quick Start screens appear. Using Quick Start is

easy. a. A backlit field shows the position of the cursor.

b. To move the cursor left or right, use the keys to the left or right of the ENTER key. To scroll up or down or to increase

or decrease the value of a digit, use the keys above and below the ENTER key. Use the left and right keys to move

the decimal point.

c. Press ENTER to store a setting. Press EXIT to leave without storing changes. Pressing EXIT also returns the

display to the initial Quick Start screen.

d. A vertical black bar with a downward pointing arrow on the right side of the screen means there are more items to

display. Continue scrolling down to display all the items. When you reach the bottom of the list, the arrow will point up.

Language

English

Francais

Espanol

Deutsch

4. Choose the desired language. Scroll down to display more choices.

5. Choose pH-independent free chlorine for sensor 1 (S1).

ppm

mg/L

Units

6. Choose the desired units for chlorine.

S2 Measurement

7. Choose pH for sensor 2 (S2). This screen appears only if you have an

FCLi-02.

ORP

Redox

Ammonia

8. Choose the desired temperature units.

9. The main display appears. The outputs and alarms (if an alarm board is present) are assigned to default values.

10. To change outputs, alarms, and other settings go to the main menu and choose Program. Follow the prompts. A

menu tree is on the following two pages. To calibrate the sensor(s) refer to section 6.0.

TREE

Calibrate

Sensor 1 (Free chlorine)

Chlorine

Zero

In process

Temperature

Sensor 2 (pH)

Buffer Cal

Auto

Select buffer (NIST, DIN19267, Ingold, Merck, or Fisher)

Select stability criteria

Manual

Standardize

Enter slope or offset

Temperature

Output 1

Output 2

Hold

Sensor 1

Sensor 2

Display

Main format configuration

Language selection

Warning (enable or disable)

Screen contrast

See next page for rest of menu tree

MENU TREE (continued)

Program

Outputs

Range (assign values to 4 and 20 mA)

Configure

Output 1 or 2

Assign sensor and measurement

Range

Scale

Dampening

Fault mode (fixed or live)

Fault value (output current)

Simulate

Alarms

Configure/Setpoint

Alarm 1, 2, 3, or 4

Setpoint

Assign sensor and measurement

High or low logic

Deadband

Interval time

On time

Recovery time

Simulate

Synchronize timers

Measurement

Free chlorine (sensor 1)

Measurement selection

Units

Filter

Resolution

pH (sensor 2)

Measurement selection

Preamplifier location

Solution temperature correction

Resolution

Filter

Reference impedance (high or low)

Temperature

Units

Temperature compensation (auto or manual)

Set manual temperature (if selected)

Security

Calibrate/Hold only

All

Diagnostic Setup

Reference Offset

Diagnostics (on or off)

Glass impedance temperature correction

Glass fault high

Reference fault high

Reset Transmitter

About This Document

This manual contains instructions for installation and operation of the Model FCLi-1056

The following list provides notes concerning all revisions of this document.

Rev. Level

Date

Notes

1/08

This is the initial release of the product manual. The manual has been

reformatted to reflect the Emerson documentation style and updated to

reflect any changes in the product offering.

08/09

Update DNV / ISO Approval

5/11

Update specifications, part numbers, add information for new pH sensor

3900, added warning and wiring diagrams in sec 3, add electrical shock

warning sec 8.0, modified instructions for cleaning the pH sensor and

replacement parts tables sec 8

03/12

Update addresses - mail and web

07/17

Changed instances of analyzer to transmitter. Replaced Rosemount

Analytical with Rosemount. Replaced Emerson Process Management

with Emerson. Updated addresses and logos and reformatted back

page.

MODEL FCLI-1056 TABLE OF CONTENTS

FCLi-1056

TABLE OF CONTENTS

Section Title Page

1.0 DESCRIPTION AND SPECIFICATIONS ................................................................ 1

1.1 Applications and Features ..................................................................................... 1

1.2

Specifications

........................................................................................................... 2

1.3 Ordering Information ................................................................................................ 3

2.0

INSTALLATION

....................................................................................................... 5

2.1 Unpacking and Inspection........................................................................................ 5

2.2

Inst

allation ................................................................................................................ 5

3.0 WIRING.................................................................................................................... 9

3.1 Preparing Conduit Openings.................................................................................... 9

3.2 Power, Alarm, Output, and Sensor Connections ..................................................... 10

4.0 DISPLAY AND

OPERATION

................................................................................... 13

4.1 Display ..................................................................................................................... 13

4.2 Keypad ..................................................................................................................... 14

4.3 Programming the Transmitter - Tutorial........................................................................ 15

4.4 Security .................................................................................................................... 16

4.5 Using Hold ............................................................................................................... 17

4.6 Configuring the Main Display ................................................................................... 18

5.0 PROGRAMMING THE TRANSMITTER ........................................................................ 19

5.1 General .................................................................................................................... 19

5.2 Default Settings........................................................................................................ 19

5.3 Configuring, Ranging and Simulating

Output

s ......................................................... 22

5.4 Configuring Alarms and Assigning Setpoints ........................................................... 25

5.5 Configuring the Measurement.................................................................................. 30

5.6 Configuring Temperature Related Settings .............................................................. 32

5.7 Configuring Security Settings................................................................................... 33

5.8 Setting up Diagnostics ............................................................................................. 34

5.9 Resetting the Transmitter ............................................................................................. 36

6.0 CALIBRATION ........................................................................................................ 37

6.1 Introduction .............................................................................................................. 37

6.2 Calibrating Temperature........................................................................................... 37

6.3 Calibration - Free Chlorine ...................................................................................... 39

6.4 Calibration - pH ....................................................................................................... 42

6.5 Calibration - Analog

Output

s .................................................................................... 49

MODEL FCLi-1056

TABLE OF CONTENTS

TABLE OF CONTENTS CONT’D

Section Title Page

7.0 DIGITAL COMMUNICATIONS ............................................................................... 51

8.0 MAINTENANCE ...................................................................................................... 53

8.1 Transmitter ................................................................................................................... 53

8.2 Chlorine Sensor ....................................................................................................... 54

8.3 pH Sensor ................................................................................................................ 56

8.4 Constant Head Flow Controller ................................................................................ 56

9.0 TROUBLESHOOTING ........................................................................................... 59

9.1 Overview .................................................................................................................. 59

9.2 Using the Diagnostic Feature................................................................................... 59

9.3 Troubleshooting When a Fault Message is Showing .............................................. 60

9.4 Troubleshooting When a Warning Message is Showing.......................................... 63

9.5 Troubleshooting When No Error Message is showing - Chlorine ............................ 64

9.6 Troubleshooting When No Error Message is showing - pH ..................................... 67

9.7 Troubleshooting When No Error Message is showing - General ............................. 70

9.8 Simulating Inputs - Chlorine ..................................................................................... 70

9.9 Simulating Inputs - pH.............................................................................................. 70

9.10 Simulating Inputs Temperature ................................................................................ 71

LIST OF

ABLES

Number Title Page

1.3

Ordering Information ...............................................................................................

1.3

Component Parts .....................................................................................................

1.3

Accessories ..............................................................................................................

1.3

Spare Parts...............................................................................................................

3.2

Sensor Wiring ...........................................................................................................

4.6

Configuring the Main Display ...................................................................................

5.1

Default Settings ........................................................................................................

5.1

Default Settings cont ................................................................................................

5.7

Configuring Security Settings ...................................................................................

5.8.2

Procedure - Setting Up Diagnostics .........................................................................

6.4

Calibration - pH ........................................................................................................

8.1

Transmitter ...................................................................................................................

8.2.3

Spare Parts ..............................................................................................................

8-2

Replacement Parts for Constant Head Flow Controller Assembly (Model FCLi-01)

................................................................................................................................

8-3

Replacement Parts for Constant Head Flow Controller Assembly (Model FCLi-02)

................................................................................................................................

9.3

Troubleshooting When a Fault Message is Showing ...............................................

9.4

Troubleshooting When a Warning Message is Showing ..........................................

9.5

Troubleshooting When No Error Message is Showing - Chlorine ............................

9.6

Troubleshooting When No Error Message is Showing - pH .....................................

MODEL FCLi-1056

TABLE OF CONTENTS

LIST OF TABLES CONT’D

9.6.1 Calibration Error During Two-Point Calibration ........................................................ 67

9.7 Troubleshooting When No Error Message is Showing - General............................. 70

9.9.2 Simulating pH Input .................................................................................................. 70

9.10 Simulating Inputs Temperature................................................................................. 72

LIST OF

FIGURES

Number Title Page

2-1 Chlorine Sensor Parts .............................................................................................. 7

2-2 Model FCLi-01 .......................................................................................................... 8

2-3 Model FCLi-02 .......................................................................................................... 8

3-1 Analog Output Connections ..................................................................................... 9

3-2 Alarm Relay Connections ......................................................................................... 10

3-3 Wiring Diagram for Free Chlorine Sensor ................................................................ 11

3-4 Wiring Diagram for 399VP-09 pH Sensor ............................................................... 11

3-5 Wiring Diagram for 3900VP-10 pH sensor (gray cable) ........................................... 11

3-6 Wiring Diagram for 3900VP-10 pH sensor (blue cable) ........................................... 11

4-1 Main Display ............................................................................................................. 13

4-2 Programming Screen Showing Item List .................................................................. 13

4-3 Arrow Bar ................................................................................................................. 13

4-4 Transmitter Keypad ...................................................................................................... 14

4.5 Navigation Keys ....................................................................................................... 14

5-1 High Alarm Logic ..................................................................................................... 26

5-2 Low Alarm Logic ...................................................................................................... 26

5-3 Operation of the Interval

imer ................................................................................. 26

6-1 Sensor Current as a Function of Free Chlorine Concentration ................................ 39

6-2 Calibration Slope and Offset .................................................................................... 42

8-1 Chlorine Sensor Parts .............................................................................................. 55

8-2 Replacement Parts for the Flow Controller Assembly used in Model FCLi-01 ......... 57

8-3 Replacement Parts for the Flow Controller Assembly used in Model FCLi-02 ......... 58

9-1 Pin Out Diagram for Model 498CL-01-VP Sensor ................................................... 61

9-2 Pin Out Diagram for Model 399VP-09 Sensor ......................................................... 61

9-3 Simulating pH Inputs ................................................................................................ 70

9-4 Three-Wire RTD Configuration................................................................................. 71

9-5 Simulating TRD Inputs.............................................................................................. 71

iii

THIS PAGE LEFT BLANK INTENTIONALLY

Model FCLi-1056 SECTION 1.0

DESCRIPTION AND

SPECIFICATIONS

SECTION 1.0. DESCRIPTION AND

SPECIFIC

TIONS

• COMPLETE SYSTEM INCLUDES sensor, connecting cable, transmitter, and flow controller

• SENSOR RESPONSE IS PRACTICALLY INDEPENDENT of pH between pH 6 and 10

• NO REAGENTS

• NO AUXILIARY pH ELECTRODE

• VARIOPOL QUICK-DISCONNECT FITTINGS makes sensor replacement easy

1.1 APPLICATIONS AND FEATURES

The FCLi free chlorine system is intended for the

determination of free chlorine (hypochlorous acid plus

hypochlorite ion) in fresh water. Unlike other free chlo-

rine transmitters, the FCLi does not use expensive

sam- ple conditioning systems or messy reagents to

control pH. Nor, does it require an auxiliary pH sensor

for pH correction. Instead, the pH adjustment takes

place inside the sensor, producing a signal that

changes less than 4% per unit change in pH between

pH 6 and

10. Below pH 6.5 the change is less than 1%. The lin-

ear range of the sensor is 0 to 20 ppm (mg/L).

The FCLi is not intended for the determination of total

or combined chlorine (like monochloramine). Nor, can

the FCLi be used for the determination of chlorine in

seawater.

The FCLi uses a three electrode, membrane-covered

amperometric sensor. The sensor consists of a

hydrophilic membrane stretched over a gold mesh

cathode. A silver/silver chloride reference electrode

and an external copper auxiliary electrode complete

the circuit. The fill solution is saturated succinic acid

slurry. During operation, an electrochemical reaction,

driven by the polarizing voltage, consumes free chlo-

rine at the cathode surface. The auxiliary electrode

provides the electrons for the cathode reaction, and

a current proportional to the reaction rate flows

between the electrodes. Because the concentration of

chlorine at the cathode is zero, free chlorine in the

sample continuously diffuses through the membrane

and is destroyed at the cathode. Thus, the cathode

current is proportional to the diffusion rate, which is

proportional to the concentration of free chlorine in the

sample.

The FCLi sensor requires neither sample pretreatment

nor pH correction. All amperometric free chlorine sen-

sors generate a raw current that depends primarily on

the concentration of hypochlorous acid. Because the

fraction of free chlorine present as hypochlorous acid

is a function of pH, readings will be in error if the sam-

ple pH changes from the value it had during calibra-

tion. To correct for pH changes, some manufacturers

treat the sample with acid to convert hypochlorite to

hypochlorous acid. Others continuously measure the

pH and use the pH value to correct the chlorine sensor

reading. The Model FCLi is different. The sensor uses

a highly buffered acidic fill solution for internal pH

adjustment. The fill solution converts all the free chlo-

rine entering the sensor as well as much of the free

chlorine at the outside surface of the membrane into

hypochlorous acid. Thus, the sensor response is prac-

tically independent of pH.

For customers who wish to measure pH, an option

that includes a pH sensor and flow cell is available.

Maintenance is fast and easy. Replacing a membrane

requires no special tools or fixtures. A screw cap holds

the pre-tensioned membrane in place. Replacing the

membrane and fill slurry takes only a few minutes.

The FCLi includes the easy-to-use Model 1056 ana-

lyzer. The transmitter features two fully programmable

20 mA analog outputs. Programming and calibration is

simple and intuitive. The backlit, four-line display

allows the user to read chlorine (and pH) at a single

glance.

Valves, rotameters, and pressure regulators to control

sample flow are things of the past with the Model

FCLi. A constant head overflow sampler ensures the

correct flow to the sensor no matter how much the

sample flow or pressure changes. To eliminate wiring

hassles, quick disconnect Variopol cable is standard.

Stable free chlorine standards do not exist. The chlo-

rine sensor must be calibrated using the results of a

laboratory test run on a grab sample.

MODEL FCLi-1056

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

1.2 SPECIFICATIONS — GENERAL

Sample requirements:

Pressure: 3 to 65 psig (122 to 549 kPa abs)

A check valve in the inlet opens at 3 psig (122

kPa abs). If the check valve is removed, mini-

mum pressure is 1 psig (108 kPa abs).

Temperature: 32 to 122°F (0 to 50°)

Minimum Flow: 2 gal/hr (7.6 L/hr)

Maximum flow: 80 gal/hr (303 L/hr); high flow

causes the overflow tube to back up.

Sample Conductivity: >10 µS/cm

Process connection: 1/4-in OD tubing compression

fitting (can be removed and replaced with barbed

fitting for soft tubing).

Drain connection: 3/4-in barbed fitting. Sample must

drain to open atmosphere.

Wetted parts:

Overflow sampler: acrylic, polycarbonate,

polyester, Kynar

, nylon, silicone

Chlorine sensor: PVC, Viton

, silicone, polyether-

sulfone, polyester, gold, and copper (or 316

stainless steel)

pH sensor (3900VP) : Stainless steel, glass,

Teflon

®2

, polyphenylene sulfide, EPDM, and

silicone

Response time to step change in chlorine concen-

tration: <120 sec to 90% of final reading for inlet

sample flow of 2 gph (7.6 L/hr).

Weight/shipping weight:

Model FCLi-01: 10 lb/13 lb (4.5 kg/6.0 kg)

Model FCLi-02: 11 lb/14 lb (5.0 kg/6.5 kg)

[rounded to the nearest 1 lb. (0.5 kg)]

SPECIFICATIONS — SENSOR

Free chlorine range: 0 to 20 ppm as Cl

. For higher

ranges, consult the factory.

Accuracy: Accuracy depends on the accuracy of the

chemical test used to calibrate the sensor

Linearity (0-20 ppm): 1% per IEC 60746

Linearity (0-2 ppm): ±0.05 ppm following calibration

at 2 ppm

Sensitivity to pH: Between pH 6.5 and 10, sensor

signal changes <4% per unit change in pH. Below

pH 6.5 the change is <1% per unit change in pH.

Interferences: Monochloramine, dichloramine,

permanganate, and peroxides

Electrolyte life: 3 months (approx.)

SPECIFICATIONS — TRANSMITTER

Case: Polycarbonate, NEMA 4X/CSA4 (IP65)

Display: Monochromatic back-lit LCD. Main character

height 0.6 in (15 mm). Display is user-programable.

Languages: English, German, Italian, Spanish,

French, Portuguese

Ambient temperature and humidity: 32 to 131°F

(0 to 55°C); RH 5 to 95% (con-condensing)

Storage temperature: -4 to 140°F (-20°C and 60°C)

Power: 85 to 265 Vac, 47.5-65.0 Hz, 15 W.

Equipment protected by double insulation.

RFI/EMI: EN-61326

LVD: EN-61010-1

Outputs: Two 4-20 mA or 0-20 mA isolated outputs.

Continuously adjustable. Linear or logarithmic.

Maximum load 550 ohms. Output dampening with

time constant of 5 sec is user-selectable.

Alarms: Four alarm relays for process meas-

urement(s) or temperature. Any relay can be

configured as a fault alarm instead of a

process alarm. Each relay can be configured

independently and each can be programmed

with interval timer settings.

Relays: Form C, SPDT, epoxy sealed

Relay Contact ratings:

5 A at 28 VDC or 300 VAC (resistive)

1/8 HP at 120/240 VAC.

Terminal Connections Rating: Power connector

(3-leads): 18-12 AWG wire size. Current output

connectors (2-leads): 24-16 AWG wire size. Alarm

relay terminal blocks: 18-16 AWG wire size

Kynar is a registered trademark of Elf Atochem North America.

Viton and Teflon are registered trademarks of DuPont

Performance Eastomers.

MODEL FCLi-1056

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

1.3 ORDERING INFORMATION

FCLi Free Chlorine Measuring System. The FCLi is a complete system for the determination of free chlorine in

aqueous samples. It consists of the sensor(s), transmitter, and constant head flow controller. All components are

mounted on a backplate. Model option -02 includes a pH sensor for customers who wish to measure pH in addi-

tion to free chlorine. Three replacement membranes and enough electrolyte chemicals to fill the sensor three

times are shipped with each sensor.

FCLi FREE CHLORINE MEASURING SYSTEM

CODE

pH CORRECTION (required selection)

Without pH sensor

With pH sensor

CODE

pH CORRECTION (required selection)

220

1056-03-24-38-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine only (option -01 only)

221

1056-03-24-32-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine and pH (option -02 only)

FCL

-02 -221 EXAMPLE

COMPONENT PARTS

TRANSMITTER

MODEL

DESCRIPTION

1056-03-24-38-AN

1056-03-24-38-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine only

1056-03-24-32-AN

1056-03-24-32-AN, 115/230 Vac 50/60 Hz, alarm relays, analog outputs, chlorine and pH

SENSOR MODEL

DESCRIPTION

498CL-01-VP

pH-independent free chlorine sensor with Variopol connector

3900VP-02-10

pH sensor with Variopol connector

SENSOR CABLE

DESCRIPTION

24150-00

Interconnecting cable, Variopol for 498ACL sensor, 4 ft

23645-08

Interconnecting cable, Variopol for 3900VP sensor (gray), 4 ft

24281-05

Interconnecting cable, Variopol for 3900VP sensor (blue), 4 ft

ACCESSORIES

PART #

DESCRIPTION

9240048-00

Tag, stainless steel (specify marking)

SPARE PARTS

PART #

DESCRIPTION

33970-00

Fill plug

33968-00

Membrane retainer

9550094

O-ring, 2-014, Viton

23501-10

pH-independent free chlorine membrane assembly, includes one membrane assembly and O-ring

23502-10

pH-independent free chlorine membrane assembly, includes three membrane assemblies and three

O-rings

24146-00

pH-independent free chlorine sensor electrolyte kit, includes three bottles of saturated succinic acid and

three bottles of succinic acid crystals

MODEL FCLi-1056

SECTION 1.0

DESCRIPTION AND SPECIFICATIONS

MODEL FCLi-1056

SECTION 2.0

INST

ALLA

TION

SECTION

2.0.

INSTALL

TION

2.1 UNPACKING AND INSPECTION

Inspect the shipping container. If it is damaged, contact the shipper immediately for instructions. Save the box.

If there is no apparent damage, unpack the container. Be sure all items shown on the packing list are present.

If items are missing, notify Rosemount immediately.

2.1.1 MODEL FCLi-01-220 (free chlorine without pH sensor)

Model consists of the following items mounted on a back plate.

1. Model 1056-03-24-38-AN transmitter with sensor cable

attached.

2. Constant head overflow sampler with flow cell for chlorine sensor.

The free chlorine sensor (Model 498CL-01-VP) is in a separate package. The sensor is shipped with three membrane

assemblies and enough electrolyte chemicals to fill the sensor three times.

2.1.1 MODEL FCLi-02-221 (free chlorine with pH sensor)

Model consists of the following items mounted on a back plate.

1. Model 1056-03-24-32-AN transmitter with sensor cables

attached.

2. Constant head overflow sampler with flow cells for chlorine and pH sensors.

3. Stand to hold buffer solution during calibration.

The free chlorine sensor (Model 498CL-01-VP) and the Model 3900VP-02-10 pH sensor, which replaces the older

Model 399VP-09 sensor, are in separate packages. The free chlorine sensor is shipped with three membrane

assemblies and enough electrolyte chemicals to fill the sensor three times.

MODEL FCLi-1056

SECTION 2.0

INST

ALLA

TION

2.2 INSTALLATION

2.2.1 General Information

1. Although the system is suitable for outdoor use, do not install it in direct sunlight or in areas of extreme

temperature.

CAUTION

The FCLi free-chlorine system is

NOT

suitable for use in hazardous areas.

2. To keep the transmitter enclosure watertight, install plugs (provided) in the unused cable openings.

3. Install the system in an area where vibrations and electromagnetic and radio frequency interference are

minimized or absent.

4. Be sure there is easy access to the transmitter and sensors.

2.2.2 Sample Requirements

Be sure the sample meets the following requirements:

1. Temperature: 32 to 122ºF (0 to 50ºC)

2. Pressure: 3 to 65 psig (122 to 549 kPa abs)

3. Minimum flow: 2 gal/hr (7.6 L/hr)

2.2.3 Mounting and Making Inlet and Drain Connections

The FCLi is intended for wall mounting only. Refer to Figure 2-2 or 2-3 for details.

A 1/4-inch OD tubing compression fitting is provided for the sample inlet. If desired, the compression fitting can

be removed and replaced with a barbed fitting. Do not remove the check valve. The threads are 1/4-inch FNPT.

The sample drains through a 3/4-inch barbed fitting. Attach a piece of soft tubing to the fitting and allow the waste

to drain to open atmosphere. Do not restrict the drain line.

Adjust the sample flow until the water level is even with the central overflow tube and excess water is flowing down

the tube. Confirm that sample is flowing through the flow cells.

2.2.4 Electrical Connections

Refer to Section 3.1 for details.

2.2.5 Installing the Sensor(s)

1. The chlorine sensor leaves the factory with a shipping membrane in place. The shipping membrane

must be removed and replaced with the chlorine membrane before putting the sensor in service. The

chlorine membrane is in a plastic bag attached to the sensor. Do not remove the shipping membrane

until you are ready to put the sensor in service.

a. Remove the red protective cap from the end of the sensor.

b. Holding the membrane end pointing up (cable connector end pointing down), unscrew the retainer cap

and remove the shipping membrane. See Figure 2.1. It is not necessary to remove the O-ring. Save the

shipping membrane. It should be reinstalled on the sensor when the sensor is not in use.

c. Still holding the membrane end pointing up, install the chlorine membrane. The chlorine membrane is in

the plastic bag attached to the sensor. Screw the retainer back in place.

MODEL FCLi-1056

SECTION 2.0

INST

ALLA

TION

cable

end

fill plug

o-ring

membrane

assembly

auxiliary

electrode

membrane

retainer cap

FIGURE 2-1. Chlorine Sensor Parts

2. If you are using a pH sensor, remove the protective cap on the sensor.

3. Install the sensors in the flow cells as shown in Figures 2.2 and 2.3. For Model FCLi-02-221, the pH sensor

must be installed as shown in Figure 2.3. The chlorine sensor sits in the flow cell and is held in place by the

union nut. The pH sensor screws into a plastic fitting, which the union nut holds in the flow cell. Be sure to

slip the union nut over the sensor before connecting the cable to the sensor.

4. The Model FCLi is provided with sensor cables pre-wired to the transmitter. Connect the chlorine sensor to

the cable labeled Chlorine Sensor. Connect the pH sensor to the cable labeled pH Sensor. The terminal end

of the sensor is keyed to ensure proper mating with the cable receptacle. Once the key has slid into the

mating slot, tighten the connection by turning the knurled ring clockwise.

NOTE

The chlorine sensor is available in two styles. One has a copper auxiliary electrode; the other has a stain-

less steel auxiliary electrode. The auxiliary electrode is the metal band visible at the bottom of the sen-

sor. The copper electrode is gradually being phased out and replaced by a stainless steel electrode.

If the sensor has a copper electrode…Generally, it is best to keep the sensor in a continuously flowing

sample. The sensor can tolerate loss of sample flow for about four days as long as it remains immersed

in water in the flow cell. A check valve in the sample inlet prevents water from draining out of the flow

cell. If the sensor sits too long in a stagnant sample, copper ions from the air oxidation of the electrode

can diffuse into the sensor. Once inside the sensor, the copper undergoes an electrochemical reaction

that greatly increases the background current and can potentially damage the sensor. See step 2 in

Section 6.3.2 for more information.

If the sensor has a

stainless

steel electrode…The stainless steel electrode is not susceptible to air oxi-

dation. Therefore, loss of sample flow does not normally present a problem.

Do not expose the chlorine sensor to air for any longer than an hour. Prolonged exposure to air will cause

the membrane to dry out. Once this happens, the membrane must be replaced.

MODEL FCLi-1056

SECTION 2.0

INST

ALLA

TION

INCH

MILLIMETER

CHLORINE SENSOR

CHECK VALVE

INLET

DRAIN

FIGURE 2-2. Model FCLi-01-220

INCH

MILLIMETER

CHLORINE SENSOR

pH SENSOR

CHECK

VALVE

INLET

DRAIN

FIGURE 2-3. Model FCLi-02-221

MODEL FCLi-1056

SECTION 3.0

WIRING

SECTION

3.0.

WIRING

3.1 POWER, ALARM, AND OUTPUT WIRING

ARNING

RISK OF ELECTRICAL SHOCK

Electrical installation must be in accordance with the National Electrical Code

(ANSI/NFPA-70) and/or any other applicable national or local code.

3.1.1 Power

Wire AC mains power to the power supply board, which is mounted vertically on the left hand side of the analyz-

er enclosure. The power connector is at the top of the board. Unplug the connector from the board and wire the

power cable to it. Lead connections are marked on the connector. (L is live or hot; N is neutral, the ground con-

nection has the standard symbol.)

AC power wiring should be 14 gauge or greater. Run the power wiring through the conduit opening nearest the

power terminal. Provide a switch or breaker to disconnect the transmitter from the main power supply. Install the

switch or breaker near the transmitter and label it as the disconnecting device for the transmitter.

3.1.2 Analog output wiring

Two analog current outputs are located on the main circuit board, which is attached to the inside of the enclosure

door. Figure 3-1 shows the location of the terminals. The connectors can be detached for wiring. TB-1 is output 1.

TB-2 is output 2. Polarity is marked on the circuit board.

For best EMI/RFI protection, use shielded output signal cable enclosed in earth-grounded metal conduit.

Keep output signal wiring separate from power wiring. Do not run signal and power or relay wiring in the same

conduit or close together in a cable tray.

FIGURE 3-1. Analog output connections. The analog outputs are on the main

board near the hinged end of the enclosure door.

MODEL FCLi-1056

SECTION 3.0

WIRING

3.1.3 Alarm wiring.

WARNING

Exposure to some chemicals may degrade the sealing

properties used in the following devices: Zettler

Relays (K1-K4) PN AZ8-1CH12DSEA

The alarm relay terminal strip is located just below the

power connector on the power supply board. See

Figure 3-2.

Keep alarm relay wiring separate from signal wiring.

Do not run signal and power or relay wiring in the

same conduit or close together in a cable tray.

FIGURE 3-2. Alarm relay connections.

3.2 SENSOR WIRING

The Model FCLi is provided with sensor cables pre-wired to the transmitter. If it is necessary to replace the

sensor cable, refer to the instructions below.

1. Shut off power to the transmitter.

2. Loosen the four screws holding the front panel in place and let it drop down.

3. Locate the appropriate signal board.

Slot 1 (left)

Slot 2 (center)

Slot 3 (right)

communication

input 1 (chlorine)

input 2 (pH)

4. Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull the board

forward to gain access to the wires and terminal screws. Disconnect the wires and remove the cable.

5. Insert the new cable through the gland and pull the cable through the cable slot.

6. Wire the sensor to the signal board. Refer to the wiring diagrams in Figures 3-3 and 3-4.

7. Once the cable has been connected to the board, slide the board fully into the enclosure while taking up the

excess cable through the cable gland. Tighten the gland nut to secure the cable and ensure a sealed enclosure.

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Rosemount FCLi Owner's manual

Rosemount FCLi Owner's manual

Rosemount FCLi Owner's manual

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